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Section Contents
1 Die Casting Alloy Cross Reference Designations
2 Aluminum Alloys
NADCA No. Format Page
3-2
3-4
3
Selecting Aluminum Alloys 3-4
Aluminum Alloy Chemical Composition A-3-1-06 Standard 3-5
Aluminum Alloy Properties A-3-2-06 Standard 3-6
Aluminum Alloy Characteristics A-3-3-06 Guidelines 3-7
3 Aluminum Metal Matrix Composites 3-8 3
Selecting Aluminum Composites 3-8
Aluminum Composites Chemical Composition A-3-4-06 Standard 3-9
Aluminum Composites Properties A-3-5-06 Standard 3-10
Aluminum Composites Characteristics A-3-6-06 Guidelines 3-11
4 Copper Alloys 3-12
Selecting Copper Alloys 3-12
Copper Alloy Chemical Composition A-3-7-06 Standard 3-13
Copper Alloy Properties A-3-8-06 Standard 3-14
Copper Alloy Characteristics A-3-9-06 Guidelines 3-15
5 Magnesium Alloys 3-16
Selecting Magnesium Alloys 3-16
Magnesium Alloy Chemical Composition A-3-10-06 Standard 3-17
Magnesium Alloy Properties A-3-11-06 Standard 3-18
Magnesium Alloy Characteristics A-3-12-06 Guidelines 3-19
6 Zinc and ZA Alloys 3-20
Selecting Zinc and ZA Alloys 3-20
Zinc and ZA Alloy Chemical Composition A-3-13-06 Standard 3-21
Zinc and ZA Alloy Properties A-3-14-06 Standard 3-22
Zinc and ZA Alloy Characteristics A-3-15-06 Guidelines 3-23
7 Selecting An Alloy Family 3-24
8 Quick Guide to Alloy Family Selection 3-25
9 Elevated Temperature Properties 3-26
10 Property Comparison 3-30
11 Cross Reference: Alloy Designation and 3-34
Composition
a Similar to preceding entry with slight variations in minor constituents. b The Federal specification for aluminum
alloy die castings uses the Aluminum Association designations for individual alloys. Military designations superseded
by Federal specifications. c Japanese specifications allow 0.3 magnesium maximum. d Japanese specifications allow
1.0 zinc maximum. e DIN 1725 spec allows 1.2 max zinc and up to 0.5 max magnesium. f DIN 1725 spec allows 0.3
max magnesium. g Alloy compositions shown in DIN 1725 tend to be “primary based” and have low impurity limits
making it difficult to correlate directly to U.S. alloys.
Table of Symbols Note: Some of these standards are obsolete but included here for historical purposes. For closest cross-reference refer to the
UNS — Unified tables of foreign alloy designations and chemical constituencies at the end of this section.
Numbering
System
ANSI — American
National
Standards
Institute Aluminum Metal Matrix Composite Alloy Specifications
ASTM — American Duralcan UNS AA
Society for
Testing and USA
Materials
F3D.10S-F 380/SiC/10p
AA — Aluminum
Association
F3D.20S-F 380/SiC/20p
SAE — Society of
Automotive F3N.10S-F 360/SiC/10p
Engineers
MIL — Military
Specifications
JIS — Japanese
Industrial
Standard
DIN — German
Industrial
Standard
ANSI — American
National
Standards
Zinc and ZA Alloy Specifications Institute
ASTM — American
Comm’l UNS ASTM Former Federal DIN JIS Society for
B86 SAE QQ-Z363a Testing and
Materials
J469
AA — Aluminum
2 Z35541 AC43A 921 AC43A 1743 Association
DIN — German
Industrial
Standard
2 Aluminum Alloys
Machining Characteristics
Machining characteristics vary somewhat among the commercially available aluminum die casting
alloys, but the entire group is superior to iron, steel and titanium. The rapid solidification rate
associated with the die casting process makes die casting alloys somewhat superior to wrought
and gravity cast alloys of similar chemical composition.
Alloy A380 has better than average machining characteristics. Alloy 218, with magnesium the
major alloying element, exhibits among the best machinability. Alloy 390, with the highest silicon
content and free silicon constituent, exhibits the lowest.
Improved wear resistance can be achieved with aluminum die castings by hard anodizing.
Where a part design does not allow the production of a pressure-tight die casting through
control of porosity by gate and overflow die design, the location of ejector pins, and the recon-
figuration of hard-to-cast features, impregnation of aluminum die castings can be used. Systems
employing anaerobics and methacrylates are employed to produce sealed, pressure-tight castings
with smooth surfaces.
A detailed discussion of fi nishing methods for aluminum die castings can be found in Product
Design For Die Casting.
Nominal Mg 0.5 Mg 0.5 Cu 3.5 Cu 3.5 Cu 2.5 Cu 3.8 Cu 4.5 Si 12.0 Si 12.0 Si 5.0 Mg 8.0
Comp: Si 9.0 Si 9.5 Si 8.5 Si 8.5 Si 10.5 Si 11.0 Si 17.0
Detailed Composit ion
Silicon
9.0-10.0 9.0-10.0 7.5-9.5 7.5-9.5 9.5-11.5 10.5-12.0 16.0-18.0 11.0-13.0 11.0-13.0 4.5-6.0 0.35
Si
Iron
2.0 1.3 2.0 1.3 1.3 1.3 1.3 2.0 1.3 2.0 1.8
Fe
Copper
0.6 0.6 3.0-4.0 3.0-4.0 2.0-3.0 3.0-4.5 4.0-5.0 1.0 1.0 0.6 0.25
Cu
Magnesium
0.4-0.6 0.4-0.6 0.10 0.10 0.10 0.10 0.45-0.65 0.10 0.10 0.10 7.5-8.5
Mg
Manganese
0.35 0.35 0.50 0.50 0.50 0.50 0.50 0.35 0.35 0.35 0.35
Mn
Nickel
0.50 0.50 0.50 0.5 0.30 0.50 0.10 0.50 0.50 0.50 0.15
Ni
Zinc
0.50 0.50 3.0 3.0 3.0 3.0 1.5 0.50 0.50 0.50 0.15
Zn
Tin
0.15 0.15 0.35 0.35 0.15 0.35 — 0.15 0.15 0.15 0.15
Sm
Titanium
— — — — — — 0.10 — — — —
Ti
Others
— — — — — — 0.10 — — — —
Each
Total
0.25 0.25 0.50 0.50 0.50 0.50 0.20 0.25 0.25 0.25 0.25
Others
Aluminum
Balance Balance Balance Balance Balance Balance Balance Balance Balance Balance Balance
Al
a Analysis shall ordinarily be made only for the elements mentioned in this table. If, however, the presence of other elements is suspected, or
indicated in the course of routine analysis, further analysis shall be made to determine that the total of these other elements are not present in
excess of specified limits. b With respect to mechanical properties, alloys A380.0, 383.0 and 384.0 are substantially interchangeable. Sources:
ASTM B85-92a; Aluminum Association.
* Two other aluminum alloys, 361 & 369, are being utilized in limited applications where vibration and wear are of concern. There are also other heat
treatable specialty alloys available for structural applications, such as the Silafonts and AA365. Contact your alloy producer for more information.
Specific Heat
BTU/lb °F 0.230 0.230 0.230 0.230 0.230 0.230 0.230 0.230
— — —
(J/kg °C) (963) (963) (963) (963) (963) (963) (963) (963)
Coefficient of Thermal Expansion
μ in/in°F 11.6 11.6 12.2 12.1 11.7 11.6 10.0 11.3 11.9 12.2 13.4
(μ m/m°K) (21.0) (21.0) (22.0) (21.8) (21.1) (21.0) (18.0) (20.4) (21.6) (22.0) (24.1)
Thermal Conductivity
BTU/ft hr°F 65.3 65.3 55.6 55.6 55.6 55.6 77.4 70.1 70.1 82.2 55.6
(W/m °K) (113) (113) (96.2) (96.2) (96.2) (96.2) (134) (121) (121) (142) (96.2)
Electrical Conductivity
% IACS 30 29 27 23 23 22 27 31 31 37 24
Poisson’s Ratio 0.33 0.33 0.33 0.33 0.33 — — — — 0.33 —
a 0.2% offset. b 500 kg load, 10mm ball. c Rotary Bend 5 x 10 8
cycles. d Notched Charpy. Sources: ASTM B85-92a; ASM; SAE; Wabash Alloys.
* Two other aluminum alloys, 361 & 369, are being utilized in limited applications where vibration and wear are of concern. There are also other
heat treatable specialty alloys available for structural applications, such as the Silafonts and AA365. Contact your alloy producer for more informa-
tion. More information can also be obtained from Microstructures and Properties of Aluminum Die Casting Alloys Book, NADCA Publication #215.
Die casting alloy selection requires evaluation not only of physical and mechanical properties,
and chemical composition, but also of inherent alloy characteristics and their effect on die casting
production as well as possible machining and final surface finishing.
This table includes selected die casting and other special characteristics which are usually
considered in selecting an aluminum alloy for a specific application.
The characteristics are rated from (1) to (5), (1) being the most desirable and (5) being the least.
In applying these ratings, it should be noted that all the alloys have sufficiently good charac-
teristics to be accepted by users and producers of die castings. A rating of (5) in one or more
categories would not rule out an alloy if other attributes are particularly favorable, but ratings of
(5) may present manufacturing difficulties.
The benefits of consulting a custom die caster experienced in casting the aluminum alloy being
considered are clear.
3
Table A-3-3 Die Casting And Other Characteristics: Al Alloys
(1 = most desirable, 5 = least desirable)
Aluminum Die Casting Alloys
Commercial: ANSI/AA 360 A360 380 A380 383 384 390* 13 A13 43 218
360.0 A360.0 380.0 A380.0 383.0 384.0 B390.0 413.0 A413.0 C443.0 518.0
Resistance to
1 1 2 2 1 2 4 1 1 3 5
Hot Cracking a
Pressure Tightness 2 2 2 2 2 2 4 1 1 3 5
Die-Filling Capacity b 3 3 2 2 1 1 1 1 1 4 5
Anti-Soldering to the Die c 2 2 1 1 2 2 2 1 1 4 5
Corrosion Resistance d 2 2 4 4 3 5 3 2 2 2 1
Machining Ease & Quality e 3 3 3 3 2 3 5 4 4 5 0.15
Polishing Ease & Quality f 3 3 3 3 3 3 5 5 5 4 1
Electroplating Ease & Quality g 2 2 1 1 1 2 3 3 3 2 5
Anodizing (Appearance) h 3 3 3 3 3 4 5 5 5 2 1
Chemical Oxide Protective Coating i 3 3 4 4 4 5 5 3 3 2 1
Strength at Elevated Temp. j 1 1 3 3 2 2 3 3 3 5 4
a Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature
ranges. b Ability of molten alloy to flow readily in die and fill thin sections. c Ability of molten alloy to flow
without sticking to the die surfaces. Ratings given for anti-soldering are based on nominal iron compositions of
approximately 1%. d Based on resistance of alloy in standard type salt spray test. e Composite rating based on
ease of cutting, chip characteristics, quality of finish, and tool life. f Composite rating based on ease and speed
of polishing and quality of finish provided by typical polishing procedure. g Ability of the die casting to take
and hold an electroplate applied by present standard methods. h Rated on lightness of color, brightness, and
uniformity of clear anodized coating applied in sulphuric acid electrolyte. i Rated on combined resistance of
coating and prolonged heating at testing temperature. Sources: ASTM B85-92a; ASM; SAE
* Two other aluminum alloys, 361 & 369, are being utilized in limited applications where vibration and wear are
of concern. There are also other heat treatable specialty alloys available for structural applications, such as the
Silafonts and AA365. Contact your alloy producer for more information.
Note: Die castings are not usually solution heat treated. Low-temperature aging treatments may be used for stress
relief or dimensional stability. A T2 or T5 temper may be given to improve properties. Because of the severe chill
rate and ultra-fine grain size in die castings, their “as-cast” structure approaches that of the solution heat-treated
condition. T4 and T5 temper results in properties quite similar to those which might be obtained if given a full T6
temper. Die castings are not generally gas or arc welded or brazed.
Machining Characteristics
Al-MMCs are significantly more abrasive to cutting tools than all other aluminum die cast and
gravity cast alloys, except for hypereutectic Al-Si alloys (those containing primary Si phases).
Coarse grades of polycrystalline diamond (PCD) tools are recommended for anything more than
prototype quantities of machining.
With the proper tooling, Al-MMC can be readily turned, milled, or drilled. However, cutting
speeds are lower and feed rates are higher than for unreinforced alloys. General machining
guidelines are described in Volume 1 of the SME Tool & Manufacturing Engineers Handbook.
Specific Heat
BTU/lb °F @ 77 °F 0.201 0.198 0.208 0.193
(J/kg °C @ 22 °C) (841.5) (829.0) (870.9) (808.1)
Average Coefficient of Thermal Expansion
μ in/in°F 10.7 9.4 11.9 9.2
(μ m/m°K) (19.3) (16.9) (21.4) (16.6)
Thermal Conductivity
BTU/ft hr°F @ 72 °F 71.6 83.2 93.0 97.1
(W/m °K @ 22 °C) (123.9) (144.0) (161.0) (168.1)
Electrical Conductivity
% IACS @ 22 °C 22.0 20.5 32.7 24.7
Poisson’s Ratio 0.296 0.287 — 0.293
a Based on cast-to-size tensile bars. b Cast-to-size test specimens. c Axial fatigue, R=0.1, RT (room temperature),
1 x 107 cycles. Source: Alcan ECP Canada
Die casting alloy selection requires evaluation not only of physical and mechanical properties,
and chemical composition, but also of inherent alloy characteristics and their effect on die casting
production as well as possible machining and final surface finishing.
This table includes selected die casting and other special characteristics which are usually
considered in selecting an aluminum matrix alloy for a specific application.
The characteristics are rated from (1) to (5), (1) being the most desirable and (5) being the least.
In applying these ratings, it should be noted that all the alloys have sufficiently good charac-
teristics to be accepted by users and producers of die castings. A rating of (5) in one or more
categories would not rule out an alloy if other attributes are particularly favorable, but ratings of
(5) may present manufacturing difficulties.
The benefits of consulting a custom die caster experienced in casting the aluminum matrix alloy
being considered are clear.
3
Table A-3-6 Die Casting and Other Characteristics: Al-MMC Alloys
(1 = most desirable, 5 = least desirable)
Duralcan Aluminum Metal Matrix Composite Alloys
Commercial: ANSI/AA F3D.10S-F F3D.20S-F F3N.10S-F F3N.20S-F
A Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature range.
B Ability of molten alloy to flow redily in die and fill thin sections. C Ability of molten alloy to flow without sticking
to the die surfaces. D Based on resistance of alloy in standard type salt spray test. E Composite rating based on
ease of cutting, ship characteristics, quality of finish, and tool life. F Composite rating based on ease and speed of
polishing and quality of finish provided by typical polishing procedures. G Ability of the die casting to take and hold
an electroplate applied by prsent standard methods. H Rated on lightness of color, brightness, and uniformity of clear
anodized coating applied in sulphuric acid electrolyte. Generally aluminum die castings are unsuitable for light color
anodizing where pleasing appearance is required. I Rating based on tensile and yield strengths at temperatures up to
500 °F (260 °C), after prolonged heating at testing temperatures. Source: Alcan ECP Canada
4 Copper Alloys
Machining
Copper alloy die castings in general are more difficult to machine than other nonferrous compo-
nents, since their excellent conductivity results in rapid heating during machining operations.
However, there are significant differences in machining characteristics among the copper alloys,
as can be determined from Table A-3-9.
Ratings in Table A-3-9 are based on free machining yellow brass as a standard of 100. Most cop-
per alloys are machined dry. Three of the six alloys listed have a rating of 80, which is excellent.
Copper alloys 878 and 865 are not difficult to machine if carbide tools and cutting oil are used.
The chips from alloy 878 break up into fine particles while alloy 865 produces a long spiral which
does not break up easily into chips.
a Analysis shall ordinarily be made only for the elements mentioned in this table. If, however, the presence of other
elements is suspected, or indicated in the course of routine analysis, further analysis shall be made to determine that the
total of these other elements are not present in excess of specified limits. b With respect to mechanical properties, alloys
A380.0, 383.0 and 384.0 are substantially interchangeable. Sources: ASTM B85-92a; Aluminum Association.
* Two other aluminum alloys, 361 & 369, are being utilized in limited applications where vibration and wear are of
concern. Contact your alloy producer for more information.
Specific Heat
BTU/lb °F @ 68 °F 0.09 0.09 0.09 0.09 0.09 0.09
(J/kg °K @ 293 °K) (377.0) (377.0) (377.0) (377.0) (377.0) (377.0)
Average Coefficient of Thermal Expansion
μ in/in°F x 10 -6 12 12 11.3 10.9 10.9 13.5
(μ m/m°C x 10 -6) (21.6) (21.6) (20.3) (19.6) (19.6) (24.3)
Thermal Conductivity
BTU•ft/(hr•ft 2•°F) @ 68 °F 48.5 48.5 49.6 16.0 16.0
—
(W/m °K @ 20 °C) (83.9) (83.9) (85.8) (27.7) (27.7)
Electrical Conductivity
% IACS @ 68 °C 22 22 22 6.0 3.0 2.0
Poisson’s Ratio 80 80 26 40 80 80
a Tensile yield strength at -0.5% extension under load. Sources: ASTM B176-93a and Copper Development.
Die casting alloy selection requires evaluation not only of physical and mechanical properties,
and chemical composition, but also of inherent alloy characteristics and their effect on die casting
production as well as possible machining and final surface finishing.
This table includes selected die casting and other special characteristics which are usually
considered in selecting a copper alloy for a specific application.
The characteristics are rated from (1) to (5), (1) being the most desirable and (5) being the least.
In applying these ratings, it should be noted that all the alloys have sufficiently good charac-
teristics to be accepted by users and producers of die castings. A rating of (5) in one or more
categories would not rule out an alloy if other attributes are particularly favorable, but ratings of
(5) may present manufacturing difficulties.
The benefits of consulting a custom die caster experienced in casting the copper alloy being
considered are clear.
3
Table A-3-9 Die Casting and Other Characteristics: Cu Alloys
(1 = most desirable, 5 = least desirable)
Copper Die Casting Alloys
Commercial: 857 858 865 878 997.0 997.5
UNS: C85700 C85800 C86500 C87800 C99700 C99750
Resistance to Hot Cracking a 2 2 3 2 2 3
Pressure Tightness 3 3 2 2 3 3
Die-Filling Capacity b 2 3 2 2 2 2
Anti-Soldering to the Die c 2 2 2 1 3 3
As Cast Surface Smoothness 3 4 2 1 3 3
Corrosion Resistance d 3 3 2 1 3 3
Machining Ease & Quality e 1 1 4 3 2 2
Polishing Ease & Quality f 3 3 3 4 3 3
Electroplating Ease & Quality g 1 1 3 2 3 3
High Temperature Strength h 3 3 3 1 3 3
A Ability of alloy to withstand stresses from contraction while cooling through hot-short or brittle temperature range.
B Ability of molten alloy to flow readily in die and fill thin sections. C Ability of molten alloy to flow without sticking
to the die surfaces. D Based on resistance of alloy in standard type salt spray test. E Composite rating based on
ease of cutting, chip characteristics, quality of finish, and tool life. F Composite rating based on ease and speed of
polishing and quality of finish provided by typical polishing procedure. G Ability of the die casting to take and hold an
electroplate applied by present standard methods. H Rating based on tensile and yield strengths at temperatures up to
500°F (260°C), after prolonged heating at testing temperature. Sources: ASTM B176-93a; R. Lavin & Sons, Inc.
5 Magnesium Alloys
Machining
The magnesium alloys exhibit the best machinability of any group of commercially used metal alloys.
Special precautions must routinely be taken when machining or grinding magnesium castings.
A ASTM B94-03, based on die cast part. B Commercial producer specifications, based on ingot. Source: International Magnesium Association.
C In alloys AS41B, AM50A, AM60B and AZ91D, if either the minimum manganese limit or the maximum iron limit is not met, then the iron/man-
ganese ratio shall not exceed 0.010, 0.015, 0.021 and 0.032, respectively. D In alloy AE42, if either the minimum manganese limit or the maximum
iron limit is exceeded, then the permissible iron to manganese ratio shall not exceed 0.020. Source: ASTM B94-94, International Magnesium Assn.
* There are additional magnesium alloys that have been and are being developed for elevated temperature and creep resistant applications. Contact
your alloy producer for more information.
Specific Heat B
BTU/lb °F 0.25 0.25 0.25 0.25 0.24 0.24 0.24
(J/kg °C) (1050) (1050) (1050) (1050) (1000) (1000) (1000)
Coefficient of Thermal Expansion B
μ in/in°F 13.8 13.8 14.2 14.4 14.4 14.5 G 14.5
(μ m/m°K) (25.0) (25.0) (25.6) (26.0) (26.0) (26.1) (26.1)
Thermal Conductivity
BTU/ft hr°F 41.8 C 30 B 36 B 36 B 35 B 40 B G 40 B
(W/m °K @) (72) (51) (62) (62) (60) (68) (68)
Electrical Resistivity B
35.8 33.0 31.8 31.8
% IACS @ 22 °C (14.1) (13.0) (12.5) (12.5) N/A N/A N/A
Poisson’s Ratio 0.35 0.35 0.35 0.35 0.35 0.35 0.35
n/a = data not available. A Rotating Beam fatigue test according to DIN 50113. Stress corresponding to a lifetime of 5 x 107 cycles. Higher values have
been reported. These are conservative values. Soundness of samples has great effect on fatigue properties resulting in disagreement among data sources.
B At 68oF (20oC). C At 212-572oF (100-300oC). D ASTM E 23 unnotched 0.25 in. die cast bar. E 0.2% offset. F Average hardness based on scattered
data. G Estimated. H 0.1% offset. I Casting conditions may significantly affect mold shrinkage. Source: International Magnesium Assn.
* There are additional magnesium alloys that have been and are being developed for elevated temperature and creep resistant applications. Contact
your alloy producer for more information.
Die casting alloy selection requires evaluation not only of physical and mechanical properties,
and chemical composition, but also of inherent alloy characteristics and their effect on die casting
production as well as possible machining and final surface finishing.
This table includes selected die casting and other special characteristics which are usually
considered in selecting a magnesium alloy for a specific application.
The characteristics are rated from (1) to (5), (1) being the most desirable and (5) being the least.
In applying these ratings, it should be noted that all the alloys have sufficiently good charac-
teristics to be accepted by users and producers of die castings. A rating of (5) in one or more
categories would not rule out an alloy if other attributes are particularly favorable, but ratings of
(5) may present manufacturing difficulties.
The benefits of consulting a custom die caster experienced in casting the aluminum alloy being
considered are clear.
3
Table A-3-12 Die Casting and Other Characteristics: Mg Alloys
(1 = most desirable, 5 = least desirable)
Magnesium Die Casting Alloys
Commercial: AZ91D AZ81 AM60B AM50A AM20 AE42 AS41B
Resistance to Cold Defects a 2 2 3G 3G 5G 4G 4G
Pressure Tightness 2 2 1G 1G 1G 1G 1G
Resistance to Hot Cracking B 2 2 2G 2G 1G 2G 1G
Machining Ease & Quality C 1 1 1G 1G 1G 1G 1G
Electroplating Ease & Quality D 2 2 2G 2G 2G — 2G
Surface Treatment E 2 2 1G 1G 1G 1G 1G
Die-Filling Capacity 1 1 2 2 4 2 2
Anit-Soldering to the Die 1 1 1 1 1 2 1
Corrosion Resistance 1 1 1 1 2 1 2
Polishing Ease & Quality 2 2 2 2 4 3 3
Chemical Oxide Protective Coating 2 2 1 1 1 1 1
Strength at Elevated Temperature F 4 4 3 3 5 1 2
A The ability of alloy to resist formation of cold defects; for example, cold shuts, cold cracks, non-fill “woody” areas,
swirls, etc. B Ability of alloy to withstand stresses from contraction while cooling through the hot-short or brittle
temperature range. C Composite rating based on ease of cutting, chip characteristics, quality of finish and tool life. D
Ability of the die casting to take and hold on electroplate applied by present standard methods. E Ability of castings to
be cleaned in standard pickle solutions and to be conditioned for pest paint adhesion. F Rating based on resistance to
creep at elevated temperatures. G Rating based upon limited experience, giving guidance only. Sources: ASTM B94-92,
International Magnesium Association.
* There are additional magnesium alloys that have been and are being developed for elevated temperature and creep
resistant applications. Contact your alloy producer for more information.
Machining Characteristics
The machining characteristics of the Zamak and ZA alloys are considered very good. High-quality
surface finishes and good productivity are achieved when routine guidelines for machining zinc
are followed.
a The magnesium may be as low as 0.015 percent provided that the lead, cadmium and tin do not exceed 0.003, 0.003
and 0.001 percent, respectively. B For the majority of commercial applications, a copper content in the range of 0.25-
0.75 percent will not adversely affect the serviceability of die castings and should not serve as a basis for rejection.
Sources: ASTM B86 and ASTM B791,
Specific Heat
BTU/lb °F 0.10 0.10 0.10 0.10 0.104 0.107 0.125
(J/kg °C) (419) (419) (419) (419) (435) (450) (525)
Coefficient of Thermal Expansion
μ in/in°F x 10 -6 15.4 15.2 15.2 15.2 12.9 13.4 14.4
(μ m/m°K) (27.8) (27.4) (27.4) (27.4) (23.2) (24.1) (26.0)
Thermal Conductivity
BTU/ft hr°F 60.5 65.3 62.9 65.3 66.3 67.1 72.5
(W/m °K) (104.7) (113) (109) (113) (115) (116) (122.5)
Electrical Conductivity
μ Ω in. 25.0 27.0 26.0 27.0 27.7 28.3 29.7
Poisson’s Ratio 0.30 0.30 0.30 0.30 0.30 0.30 0.30
a 0.2% offset, strain rate sensitive, values obtained at a strain rate of 0.125/min (12.5% per minute). B 0.1% offset. C Compressive strength. D
500 kg load, 10 mm ball. E ASTM 23 unnotched 0.25 in. die cast bar. F Rotary Bend 5 x 108 cycles. G Varies with stress level; applicable only for
short-duration loads. Use 107 as a first approximation. Source: International Lead Zinc Research Organization.
Die casting alloy selection requires evaluation not only of physical and mechanical properties,
and chemical composition, but also of inherent alloy characteristics and their effect on die casting
production as well as possible machining and final surface finishing.
This table includes selected die casting and other special characteristics which are usually
considered in selecting a zinc alloy for a specific application.
The characteristics are rated from (1) to (5), (1) being the most desirable and (5) being the least.
In applying these ratings, it should be noted that all the alloys have sufficiently good charac-
teristics to be accepted by users and producers of die castings. A rating of (5) in one or more
categories would not rule out an alloy if other attributes are particularly favorable, but ratings of
(5) may present manufacturing difficulties.
The benefits of consulting a custom die caster experienced in casting the zinc alloy being consid-
ered are clear.
3
Table A-3-15 Die Casting and Other Characteristics: Zn and ZA Alloys
(1 = most desirable, 5 = least desirable)
Zamak Die Casting Alloys
Commercial: ANSI/AA No. 2 No. 3 No. 5 No. 7 ZA-8 ZA-12 ZA-27
AG-40A AG-41A AG-40B
Resistance to Hot Cracking a 1 1 2 1 2 3 4
Pressure Tightness 3 1 2 1 3 3 4
Casting Ease 1 1 1 1 2 3 3
Part Complexity 1 1 1 1 2 3 3
Dimensional Accuracy 4 2 2 1 2 3 4
Dimensional Stability 2 3 3 2 2 2 1
Corrosion Resistance 2 3 3 2 2 2 1
Resistance to Cold Defects A 2 2 2 1 2 3 4
Machining Ease & Quality C 1 1 1 1 2 3 4
Polishing Ease & Quality 2 1 1 1 2 3 4
Electroplating Ease & Quality D 1 1 1 1 1 2 3
Anodizing (Protection) 1 1 1 1 1 2 2
Chemical Coating (Protection) 1 1 1 1 2 3 3
A The ability of alloy to resist formation of cold defects; for example, cold shuts, cold cracks, non-fill “woody” areas, swirls, etc. B Ability of
alloy to withstand stresses from contraction while cooling through the hot-short or brittle temperature range. C Composite rating based on ease
of cutting. Chip characteristics, quality of finish and tool life. D Ability of the die casting to take and hold an electroplate applied by present
standard methods. Source: International Lead Zinc Research Organization.
Overview
Although this product specifications standards document addresses copper and metal matrix
composites (MMC), the four main alloy families are Aluminum, Zinc, Magnesium, and Zinc-Alumi-
num. This subsection is presented to assist in selecting an alloy family, which is the precursor to
selecting a specific alloy within a family. Information on selecting the specific alloys is presented
at the beginning or each alloy family subsection.
Typical considerations in selecting an alloy family include; alloy cost and weight, die casting
process cost, structural properties, surface finish, corrosion resistance, bearing properties and
corrosion resistance, machinability, thermal properties, and shielding (EMI/electrical conductivity).
Structural Properties
Each alloy has a unique set of properties. However, if one is in search of one or two properties
that are most important for a specific design or interested in which properties are characteristic
of an alloy family, the following generalizations may be helpful. Aluminum alloys yield the highest
modulus of elasticity. Magnesium alloys offer the highest strength-to-weight ratio and the best
dampening characteristics. The zinc alloys offer the highest ductility and impact strength. The ZA
alloys offer the highest tensile and yield strength.
Corrosion Resistance
Corrosion resistance varies from alloy family to alloy family and within an alloy family. If corro-
sion resistance is a concern, it can be improved with surface treatments and coatings. Refer to
the information on selecting specific alloys at the beginning of each alloy family subsection to see
which specific alloys yield higher corrosion resistance.
Machinability
Even though die castings can be produced to net or near-net shape, machining is often required.
When required, machining is easily accomplished on all of the die casting alloys. Magnesium,
however offers the best machinability in terms of tool life, achievable finish, low cutting forces and
energy consumption.
3
8 Quick Guide to Alloy Family Selection
3 100° 39.1 16
150° 34.8
212° 28.2 30 3
300° 18.1
-40° 54.3 2
-18° 53.6 3
70° 48 7
5 100° 46.4 13
150° 42.3
212° 35.5 23
300° 19.8
-40° 59.7
-18° 58.7
70° 54 8
8 100° 49.3
150° 42.7
212° 33.3
300° 19.5
The values in this table are from various sources and represent typical values. These values
do not represent design minimums and should be used for reference only.
10 Property Comparison
Yield Strength
psi x103 32 33 29 30 42 31 39 46 54 55
(MPa) (221) (228) (198) (208) (290) (211) (268) (320) (371) (376)
Elongation
% in 2in. 10 7 1.7 1.3 8 1.5 2.2 5 4.6 2.5
Young’s Modulus
psi x10 6 > 12.4 > 12.4 12.4 12.4 12.4 12.0 12.0 12.0 11.3 11.3
(MPa x 103) (> 85.5) (> 85.5) (85.5) (85.5) (85.5) (82.7) (82.7) (82.7) (77.9) (77.9)
Torsional Modulus
psi x10 6 > 4.8 > 4.8 4.8 4.8 4.8 4.6 4.6 4.6 4.3 4.3
(MPa x 103) (> 33.1) (> 33.1) (33.1) (33.1) (33.1) (31.7) (31.7) (31.7) (29.6) (29.6)
Shear Strength
psi x103 31 38 35 40 37 > 35 43 42
N/A N/A
(MPa) (214) (262) (241) (275) (253) (241) (296) (292)
Hardness
(Brinell) 82 91 85 87 103 94 89 100 113 114
Impact Strength
ft-lb 43 48 15 31 19 21 35
N/A N/A N/A
J (58) (65) (20) (42) (25) (29) (48)
* Minimum Properties
** Complies with ASTM specification B86.
*** Complies with ASTM specification B669.
Char t
Aluminum Magnesium Iron Plastic
380 319 356-T6 713 -F* 6061-T6 AZ-91D AM60B Clas 30 32510
Die Die Sand Sand Sand Wrought Die Die Gray Cast Malleable ABS Nylon 6
Cast Cast Cast Cast Cast Cast Cast Iron Iron (30%
Glass
Filled)
3
62 47 27 33 32 45 34 32 31 50 8 22
(426) (324) (186) (228) (220) (310) (234) (220) (214) (345)
54 24 18 24 22 40 23 19 18 32
(371) (165) (124) (165) (150) (276) (159) (130) (124) (221)
47 27 22 26 30 20 43 45
— N/A
(325) (186) (152) (179) (—) (138) 296 (310)
9 3 4 8 2.7 5 40-65
— — nil
(13) (4) (5) (11) (3.7) (6) (54-88)
52 19 25 23 19 109
N/A — — N/A
(359) (131) (172) (159) (130) (752)
Melting Range
°F 718-728 717-727 707-759 707-759 707-759 710-810 710-810 710-810 708-903 708-903
(°C) (381-387) (380-386) (375-404) (375-404 (375-404 (377-432) (377-432) (377-432) (376-484) (376-484)
Electrical Conductivity
% IACS 27 26 27.7 27.7 27.7 28.3 28.3 28.3 29.7 29.7
Thermal Conductivity
BTU/ft hr°F 65.3 62.9 66.3 66.3 66.3 67.1 67.1 67.1 72.5 72.5
(W/m °K) (113.0) (108.9) (114.7) (114.7) (114.7) (116.1) (116.1 (116.1 (125.5) (125.5)
Pattern Shrinkage
in/in or mm/mm 0.006 0.006 0.010 0.010 0.007 0.013 0.013 0.0075 0.013 0.013
Char t
Aluminum Magnesium Iron
380 319 356-T6 713 -F* 6061-T6 AZ-91D AM60B Clas 30 32510
Die Cast Die Cast Sand Sand Sand Wrought Die Cast Die Gray Cast Malleable
Cast Cast Cast Cast Iron Iron
708-903 1000-1100 960-1120 1035-1135 1100-1180 1080-1205 875-1105 1005-1140 >2150 >2250
(376-484) (538-593) (516-604) (557-613) (593-638) (—) (468-596) (540-615) (>1177) (>1232)
Cross Reference of Equivalent A luminum A lloy Specif icat ions and Desig nat ions
Designation
Q Q - A - 371c .
A A Number
No. System
Old ASTM
Germany
Kingdom
ASTM or
Unif ied
Fo r m e r
Canada
United
Japan
ANSI
UNS
SAE
ISO
JISH
360 360 AO3601 309 SG 100B 360 — LM2 530Z — —
ADC3
JISH
380 380 AO3801 306.308 SC84A-B 380 143 LM24 5302 — —
ADC10
JISH
383 383 AO3831 306.308 — — — — 5302 — —
ADC12
B390 — AO3901 — — — — — — — —
JISH
413 13 AO4131 305 S12A.B 13 162 LM6 5302 — —
ADC1
UNITED KINGDOM
3
B.S.1490 Cu Mg Si Fe Mn Ni Zn Pb Sn Ti Others
LM2 0.7-2.5 0.30 9.0-11.5 1.0 0.5 0.5 2.0 0.3 0.2 0.2 —
LM6 0.1 0.10 10.0-13.0 0.6 0.5 0.1 0.1 0.1 0.05 0.2 —
LM18 0.1 0.10 4.5-6.0 0.6 0.5 0.1 0.1 0.1 0.05 0.2 —
LM24 3.0-4.0 0.30 7.5-9.5 1.3 0.5 0.5 0.3 0.3 0.2 0.2 —
LM26 2.0-4.0 0.5-1.5 8.5-10.5 1.2 0.5 0.1 0.2 0.2 0.1 0.2 —
GERMANY
Cu Mg Si Fe Mn Ni Zn Pb Sn Ti Each Total
GD-Al-Si8Cu3 2.0-3.5 0-0.3 7.5-9.5 1.3 0.2-0.5 0.3 0.7 0.2 0.1 0.15 0.05 0.15
GD-Al-Si10Mg 0.10 0.20-0.50 9.0-11.0 1.0 0-0.4 — 0.1 — — 0.15 0.05 0.15
ISO
Cu Mg Si Fe Mn Ni Zn Pb Sn Ti Each
Al-Si8Cu3Fe 2.5-4.0 0.3 max 7.5-9.5 1.3 0.6 0.5 1.2 0.3 0.2 0.2 0.5 max
max max max max max max max
Al-Si10Mg 0.1 0.15-0.40 9.0-11..0 0.6 0.6 0.05 0.1 0.05 0.05 0.2 —
max max max max max max max max
C R O S S R E F E R E N C E O F E Q U I VA L E N T M AG N E S I U M
A L L OY S P E C I F I C AT I O N S A N D D E S I G N AT I O N S
U.S.A STM ISO 16220 EN-1753/1997
AX91D MgAl9Zn1 AZ91
AM60B MgAl6Mn AM60
AM50A MgAl5Mn AM50
AM20 MgAl2Mn AM20
AS21 MgAl2Si AS21
AS41B MgAl4Si AS41
Cross Reference of Equivalent Mag nesium A lloy Specif icat ions and Desig nat ions
U. S. ASTM %Al %Zn %Mn %Si % Fe %Cu %Ni 0 E a c h Fe/ M n M a x .
AZ91D 8.3-9.7 0.35-1.0 0.15-0.50 0.10 0.005 0.030 0.002 0.01 0.032***
AM60B 5.5-6.5 0.22 0.24-0.6 0.10 0.005 0.010 0.002 0.02 0.021**
AM50A 4.4-5.4 0.22 0.26-0.6 0.10 0.004 0.010 0.002 0.02 0.015**
AM20 — — — — — — — — —
AS21 — — — — — — — — —
AS41B 3.5-5.0 0.12 0.35-0.7 0.50-1.5 0.0065 0.02 0.002 0.02 0.010**
ISO 16220
MgAl9Zn1 8.3-9.7 0.35-1.0 0.15-0.50 0.10 0.005 0.030 0.002 0.01 0.032**
MgAl6Mn 5.5-6.5 0.2 0.2 0.24-0.60 0.10 0.005 0.010 0.002 0.01 0.021*
MgAl5Mn 4.4-5.5 0.2 0.26-0.60 0.10 0.004 0.010 0.002 0.01 0.015*
MgAl2Mn 1.6-2.6 0.2 0.33-0.70 0.10 0.004 0.010 0.002 0.01 0.012*
MgAl2Si 1.8-2.6 0.2 0.18-0.70 0.7-1.2 0.004 0.010 0.002 0.01 0.022*
MgAl4Si 3.5-5.0 0.2 0.18-0.70 0.5-1.5a 0.004 0.010 0.002 0.01 0.022*
EN-1753/1997
AZ91 8.3-9.7 0.35-1.0 min. 0.1 0.10 0.005 0.030 0.002 0.01 —
AM60 5.5-6.5 0.2 min. 0.1 0.10 0.005 0.010 0.002 0.01 —
AM50 4.4-5.5 0.2 min. 0.1 0.10 0.005 0.010 0.002 0.01 —
AM20 1.6-2.6 0.2 min. 0.1 0.10 0.005 0.010 0.002 0.01 —
AS21 1.8-2.6 0.2 min. 0.1 0.7-1.2 0.005 0.010 0.002 0.01 —
AS41 3.5-5.0 0.2 min. 0.1 0.50-1.5 0.005 0.010 0.002 0.01 —
Cross Reference of Equivalent Zinc A lloy Specif icat ions and Desig nat ions
U. S. United
ASTM SAE Canada Japan Germany ISA EN
Commercial Kingdom
#3 AG40A 903 AG40 A Class 2 Z400 ZnAl4 ZnAl4P
#5 AC41A 905 — B Class 1 Z410 ZnAl4Cu1 ZnAl4Cu1P
Cross Reference of Equivalent Zinc A lloy Specif icat ions and Desig nat ions
E N 12 8 4 4 % Al % Cu % Mg % Pb % Cd % Sn % Fe % Ni % Si
ZnAl4-P 3.7-4.3 0.1 0.025-0.06 0.005 0.005 0.002 0.05 0.02 0.03
ZnAl4Cu1-P 3.7-4.3 0.7-1.3 0.4-0.6 0.005 0.005 0.002 0.05 0.02 0.03